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5-7

10 - 15

Industry News

16 - 17

Maintec Review

21

Contacts

Selling Maintenance To Management

Energy Management

24 & 25

Steam System Maintenance

26 - 30

Compressed Air

36 - 37

Product Spotlight – Dataloggers

40 - 41

Products Spotlight – Descaling

42 & 43

Pumps and Valves.

48

Hydraulic Repairs

Publisher Michael Dominguez

Editorial editors/contributing: Jon Barret, Christer Idhammar, Alan France

Advertising Paul Clappison - Magazine Paul Miles - Online Advertising

Email Info@engineeringmaintenance.info

Website www.engineeringmaintenance.info

Phone tel: +44(0)1634 731646 Fax: +44(0)1634 631644

Address MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ

49 & 50

Buyers Guide.


INDUSTRY NEWS

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engineeringmaintenance.info March/April 2011


MAINTENANCE BEST PRACTICE

SELLING MAINTENANCE TO MANAGEMENT

We, in maintenance, often complain about how hard it is for us to “sell maintenance to top management”. There are several things we can improve upon when we talk to top management. In this article, I will outline typical situations that I have seen in industry and offer some suggestions. THE PROBLEM STATEMENT IS WRONG For people in maintenance, the word “maintenance” should mean something more than repairs. However, for people less experienced, “maintenance” often means just repairing stuff and, hopefully, doing that on an expedient basis. The product of maintenance work is not repairs or service to operations. The product of any effective maintenance department is equipment reliability. Do you see the difference? If reliability is the product from a maintenance department, repairs will be done in a planned and scheduled fashion with great attention to detail. Shafts will be aligned to onethousandth of an inch, we will balance equipment to 1.0 G, lubricants will be filtered to 3 microns, etc.

If the product is repair and service, it can be done in any fashion. Advice 1: Change the problem statement to “How do we sell equipment reliability to top management?” IT STARTS WITH THE MAINTENANCE BUDGET

A process industry company that my firm worked with set its maintenance budget at $14 million. It was $14.5 million the previous year. The maintenance budget was decided with little or no information on the actual need of maintenance in the plant. The company figured that the cost of maintenance should improve over time and, therefore, go down. It was determined that $14 million was the right number. The maintenance engineeringmaintenance.info March/April 2011

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engineeringmaintenance.info March/April 2011


MAINTENANCE BEST PRACTICE

manager hadn’t provided a different suggestion, nor did he have an (official) opinion about the new budget. In my opinion, every maintenance manager should have a five-year plan where all big and costly maintenance jobs are listed and, hopefully, spread somewhat evenly over the years. He or she should present this plan to plant and corporate managers. If reliability is managed well, the maintenance budget varies from year to year - sometimes up, sometimes down - but the general trend is down because we work on reliability improvements. Each year, a detailed maintenance budget should be built based on the needs of the plant. A realistic and trustworthy budget must be estimated starting from scratch (zero-based budgeting). Advice 2: Build a five-year maintenance budget/ plan that contains all major maintenance jobs that you know of and build a budget each year from scratch to present to management. BE SPECIFIC

If you talk to someone less knowledgeable on any subject, make sure you are specific. That way, people can understand and believe your reasoning. A maintenance supervisor that I know wanted operations to inspect and clean motors. He argued hard that motors will last longer if they are maintained correctly. Operations agreed but didn’t do anything to counter the usual excuses people use when they don’t want to do something. The argument maintenance presented was correct but unspecific. Instead, our firm helped the supervisor put together a 10-year plan for a typical motor vs. a good motor for the operations and mill managers. We discussed costs for a specific motor of importance over 10 years. The example was specific, and we did it for several motors in the plant. Management understood the full extent of the request to clean and inspect motors, and did so because it was specific. The costs associated with doing nothing were compelling.

Advice 3: Be specific in your arguments in order to put a scale to benefits and costs. WHAT’S RELIABILITY WORTH TO YOUR PLANT?

If you are going to present a case to improve reliability, you need to talk in simple financial terms, and you need to have the courage to make a commitment to the potential results. Your machine, area, line or plant should have a financial number on downtime cost. Once there is a number for downtime cost, the number can be used when estimating downtime savings (maintenance language) to dollars (management language). In many plants, the downtime cost is situational to production at that time, which makes the calculation a bit cumbersome. However, it can usually be accomplished. Advice 4: Since the product of maintenance is reliability, you must know what your product is worth. Calculate the cost of downtime. Idcon do consulting and training in maintenance management, preventive maintenance, planning and scheduling, failure analysis, spare parts management and more.

About Idhammar The author of this article is Tor Idhammar, President of IDCON, INC. Established in Sweden 1972 as Idhammar Konsult AB and in USA in 1985. Ph: + 1 919-723-2682 email: info@Idcon.com

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STEAM & HOT WATER SYSTEMS

SPIRAX SARCO STEAM SYSTEM EXPERTISE HELPS GTM GET BIOSOLIDS TREATMENT GOING FOR ANGLIAN WATER Steam and hot water systems from Spirax Sarco are helping Anglian Water treat sewage sludge at two new biosolids treatment works in Kings Lynn and Great Billing. The projects are two of four ground breaking schemes planned by the utility company to reduce biosolids volumes, increase quality and generate energy in the process. This innovative process will not only make the centres selfsufficient in electricity but any surplus will be exported on to the national grid. Spirax Sarco expertise was brought in to provide consultancy on the specification, design and installation of the steam systems for both sites. A number of Spirax Sarco specialists in condensate recovery, steam trapping and water treatment worked in partnership with the projects’ contractors to design an easily maintainable system with minimal downtime. “We didn’t have a great deal of experience with steam systems,” says Imtech Process Engineer Adrian Jaques. “So we contacted Spirax Sarco and designed the scheme together with them. They were knowledgeable, good to work with and very helpful throughout the projects. In fact I can’t praise them enough.” Spirax Sarco supplied boiler feed tanks and all the steam equipment associated with the standby, dual fuelled steam boilers at both Kings Lynn and Great Billing. These boilers are used during start-up and also during very cold weather when they are sometimes needed to supplement the steam from the CHP plants’ waste heat boilers. The company also supplied steam-to-hot-water EasiHeat systems to provide standby hot water for both sites. The Spirax Sarco systems are predominantly used during startup, providing steam and hot water to drive the treatment processes. Both projects have been built by Imtech as part of the Galliford

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engineeringmaintenance.info March/April 2011

Try Imtech Process (GTM) consortium. The Kings Lynn plant has now been operating for almost 3 years, processing sludge equivalent to around 19,000 tonnes a year of dry solids. The Great Billing plant will treat 38,700 tonnes of solids a year and was commissioned in late 2009 early 2010. Although they vary in size, both sites operate similar processes to treat the sewage sludge or biosolids, which are a byproduct of wastewater treatment. First, the sludge is heated by hot o water to 42 C and hydrolysed to break up some of the bigger o molecules. It is then steam heated to 55 C to pasteurise it and destroy any pathogens. Microorganisms continue to break down the pasteurised sludge even further in an anaerobic digestor, where they convert a substantial proportion of it into biogas. This biogas fuels an onsite combined heat and power (CHP) plant, which generates electricity, steam and hot water. The result is a 40% reduction in the volume of sludge. It is also free from pathogens such as Salmonella and E. coli and can therefore be used safely by farmers as a fertilizer substitute.


INDUSTRY NEWS

A NEW PORTABLE VIBRATION ANALYZER — WITH FULL COLOUR DISPLAY, FAST DATA ACQUISITION AND POWERFUL DIAGNOSTICS TOOLS. The VIBXPERT II handheld vibration analyzer combines the advantages of a rapid processor with a brilliant energy-efficient colour VGA display. Enhanced with an Fmax of 51KHz and up to 102,400 Lines of Resolution, all machinery problems can be captured and easily analyzed on the VIBXPERT II large colour screen.

Alarm notifications based on ISO standards or user-defined standards are visually identified with the aid of coloured LEDs. VIBXPERT II is lightweight vibration meter —only 1.2Kg! Its robust housing is dustproof and water resistant (IP65). VIBXPERT II is delivered with a carrying pouch with includes a breakaway shoulder strap for safety during data collection. The VIBXPERT II vibration analyzer features modular functionality including dynamic balancing, extended time waveform recording, transient data capture, UFF file export, Modal/ODS support and more. As with all Pruftechnik vibration data collectors with the new

The VIBXPERT II Basic platform is a 1-channel vibration data

VIBXPERT II you will enjoy the benefits of free updates, low

collector which can be upgraded at any time to 2 individually

ownership cost and unlimited tech support from the proven

configured channels via a special pass code it’s user

leaders of maintenance technology.

upgradable and does not require hardware changes.

Optionally available:  

All forms of machine vibrations, bearing conditions, process

Modules for Dynamic Balancing, Recording, Modal Analysis

data and visual inspection information can be collected

and Operation Deflection Shape (ODS) and VIBCODE

and stored on the expandable Compact Flash Card (up to

automatic measurement location identification.

8 gigabyte) for report generation or for later transfer to the OMNITREND software for further analysis, reporting and archiving. The VIBXPERT II vibration analyzer provides an easy-touse icon driven platform that offers comprehensive analysis

For details and our free 180 page guide to Condition Monitoring, Laser Shaft Alignment and Dynamic Balancing contact

functionality for the diagnosis of simple or very complex

Pruftechnik Ltd, Plant Lane Business Park,

vibration problems. Capabilities include order spectrum, phase,

Burntwood WS7 3GN

cepstrum, cross-channel phase, orbits, run-up and coastdown measurements, bump test, negative averaging and more.

or phone 01543 448350, Fax 01543 275472,

Analysis tools, including various cursor types, machine-specific

email pposte@pruftechnik.co.uk

frequency markers, signal post processing, and extensive

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bearing databases are included for evaluating each spectrum.

engineeringmaintenance.info March/April 2011


INDUSTRY NEWS

TEEKAY COUPLINGS HAVE BEEN SELECTED FOR USE ON THE ROYAL NAVY QUEEN ELIZABETH CLASS AIRCRAFT CARRIERS Leading UK specialist pipe coupling manufacturer Teekay Couplings Ltd. is pleased to announce that they are supplying their patented fire-protected pipe couplings to the Queen Elizabeth Class Aircraft Carriers – the largest vessels to enter service with the Royal Navy. The Queen Elizabeth Class vessels are 65,000 tonne aircraft carriers, 280m in length with accommodation for up to 1600 people. The vessels are being built in multiple stages at major shipyards around the UK. Teekay Axilock-FP Pipe Couplings have been selected for joining steel, copper nickel and GRE plain end pipes on the QEC project. Joining plain end pipes with Teekay Couplings avoids the need for welding, flanging, threading or grooving the pipe. The use of Teekay Couplings instead of traditional steel flange sets will considerably reduce the space, weight, time and cost of the installed pipework system. Teekay Axilock-FP Pipe Couplings comply with MoD shock and fire protection requirements for use on Naval Vessels and are fully compliant with current IACS regulations. Director, Ian Webb says “Following on from the success of the Type 45 project, we are delighted that the Teekay Axilock-FP has once again been selected as the pipe coupling of choice by our leading shipbuilders. We can now say that the global marine industry and the marine regulatory bodies have fully embraced the technological leap made by our high level of shock and fire protection. From workboats to mega-yachts, from cruise vessels to military ships, Teekay proves to be the first choice again and again.”

Image Left: Teekay Axilock-FP Pipe Coupling Recent Activity A major cruise vessel builder in Northern Europe is currently using 50,000 couplings per year. Teekay Couplings Ltd. has completed the supply of Axilock-FP couplings for the Type 45 Anti-Air Warfare Destroyer Project, the backbone of the Royal Navy’s future air defence capability The New Orleans reconstruction programme has placed several orders for Teekay pipe couplings including the first, recently introduced, ‘top of the range’ 4115mm diameter coupling for water pipelines. A major dry docks is fitting 800 couplings on two seismic survey vessels. A Danish water industry contractor has ordered 3,000 Teekay pipe couplings for a new water treatment facility. Contact: Chris Webb - Teekay Couplings Ltd chris.webb@teekaycouplings.com tel: +44 (0)1494 679500 www.teekaycouplings.com

INDUSTRY NEWS

HI-LINE STRENGTHENS CUSTOMER SERVICES TEAM Hi-line are pleased to announce the recent appointment of Nigel Winfield to the management team, reporting directly to company directors, Steven Smith and Michael Thurlow. Nigel joins Hi-line with a logistics and transportation background and was recently the operations manager for a large international transport company. Nigel’s role at Hi-line is to interface between the directors and the management team to implement business strategy and corporate policy whilst also heading up the office staff. Hi-line, suppliers of compressed air equipment, are expanding their business model and will benefit from the management skills that Nigel has gleaned from many years experience of implementing new systems into growing companies. The world is a global marketplace for Hi-line, with suppliers and customers in many geographies. Nigel’s objective will be to strengthen customer services by pulling these contacts together, making the supply chain fast, simple and efficient. Nigel was born locally to the Hi-line head office location at Burton on Trent. He is married to Karen with five children and is a keen cricketer with a passion for live music. We welcome Nigel to Hi-line and wish him every success for the future.

Further information is available from: Hi-line Industries Ltd, 5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PG Telephone: 01283 533377 Fax: 01283 533367 e-mail: enquiries@hilineindustries.com Website: www.hilineindustries.com

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INDUSTRY NEWS

MINIATURE RH SENSOR FROM MICHELL PROVIDES RELIABLE MEASUREMENTS IN HIGH HUMIDITIES Many RH instruments installed in high-humidity applications suffer from poor reliability because the electronics are exposed to the harsh, damp environment. The miniature PCmini52 probe from Michell Instruments overcomes this problem with electronics that are encapsulated in a protective resin and so are completely protected from the atmosphere. This gives the instrument an IP65 rating and enables the probe to provide reliable measurements no matter how high the surrounding humidity. The PCmini52 humidity transmitter uses a capacitive thin-film polymer sensor which either absorbs or releases water vapor as the relative humidity of the ambient air rises or drops. These sensors, developed by Michell’s Coreci division, offer both a fast response and excellent sensitivity to fluctuations in humidity. The PCmini52 is a flexible option, offering different output voltages. In addition to its miniature size, it can be configured

with both plastic and stainless steel housing for additional protection. A low power consumption of 3mA (output 0-1 Volt) makes the PCmini52 flexible enough for battery operated or wireless applications as well as fixed installations. If you would like more information please contact: Sarah Lawrence - Michell Instruments Lancaster Way Business Park, Ely, Cambridgeshire, CB6 3NW, UK Tel - +44(0)1353 658 000 Fax - +44(0)1353 658 199 e-mail – sarah.lawrence@michell.com

If it doesn’t say AirBench on the front… Reflecting their position as UK leaders in downdraught extraction, and to clarify the focus of the company for customers, suppliers, and end users, WorkPoint Environments Ltd has a new name – AirBench Ltd. “Customers know we are the company to talk to for downdraught extraction, having been UK market leaders for over 17 years”, said MD Simon Cook. “Our new name reflects our current business model and strategy.” AirBench Ltd continues to supply a wide range of downdraught benches for fume and dust extraction.

visit www.AirBench.com for more information. 12

engineeringmaintenance.info March/April 2011


INDUSTRY NEWS

NEW PAT ADAPTOR FOR 3 PHASE EQUIPMENT TESTING Seaward has introduced a specialist new adaptor to extend the range of electrical safety tests that can be carried out on 3-phase equipment. In many cases this type of industrial equipment is fitted with electronic control circuitry which makes insulation testing inappropriate. In such cases the insulation should be assessed by measurement of the protective conductor current. The new Seaward TPA test adaptor makes this possible and allows specialist factory, industrial and workshop equipment to be included as part of in-service inspection and testing protocols as required by the IEE Code of Practice. The specially designed new Seaward TPA unit is available with 16A or IEC 60309/ BS4343 compatible plugs and sockets allowing it to be connected in-line with the 3-phase supply to measure the current flowing in the protective conductor. The TPA has been developed for use with the new Seaward PrimeTest 250 PAT and extends range of measurements that can be performed on 3-phase equipment using a lightweight and highly portable handheld tester. The test adaptor is connected to the PrimeTest 250 allowing quick and easy measurement of the earth continuity without removing covers or disconnecting wires to gain access to the protective conductor in the in-coming supply. When the 3-phase appliance is operating, the protective conductor current measured by the test adaptor is shown on the PrimeTest 250 display. The new hand held PrimeTest 250 is the first electrical tester in its class to provide all the electrical tests required for compliance with the IEE Code of Practice for the In-Service

Inspection and Testing of Electrical Equipment – and also includes a host of other features. These additional tests include an RCD trip time test and a 250V DC insulation test suitable for testing sensitive electrical appliances and surge protected leads. The Seaward TPA and Primetest 250 form part of a comprehensive range of portable appliance testers and accessories that meet all workplace electrical safety testing needs.

More from www.seaward.co.uk

ENSURE RELIABLE GAS DETECTION WITH NEW DRAEGER WIRELESS SAFETY NET Operating as an all-round safety network, the new Draeger X-zone 5000 uses wireless technology to automatically connect multiple monitors for reliable, continuous detection of toxic, combustible and explosive gases. Ensuring that personnel have the confidence to work worry free, even in the most dangerous environments, these transportable units are quick to deploy and easy to set up. Issuing a loud alarm as soon as a gas is detected, they also change colour to clearly identify the alarm status. The areas where gas has been detected are indicated by red visual alarms. Safe atmospheres and, therefore, a safe escape route are confirmed by green visual alarms. By simply placing Draeger X-zone 5000 units around potentially dangerous areas or where maintenance or shutdown work is being carried out, these robust, waterproof units will ensure increased levels of safety in any application. As soon as one of the units detects a gas it immediately transmits an alarm to each of the others, warning everyone in the area that a danger exists. At the same time, a loud evacuation alarm is emitted and a patented 360Âş alarm amplifier ensures that it is heard with the same intensity in all directions. Up to 25 Draeger X-zones can be used at any one time, forming a complete wireless network to suit the specific application, including those where an explosion hazard might

exist. In addition to Zone 0 ATEX performance, they also offer a lower cost of ownership by combining flexible monitoring capabilities with a long sensor life and enhanced battery performance. Allowing gas ingress from every side, it can be fitted with up to four sensors to detect as many as five gases at once. The Drager X-zone 5000 provides simultaneous measurement of gases and vapours such as hydrocarbons, hydrogen and other explosive, combustible or toxic gases. Unlike portable instruments which usually leave the scene with the wearer, the Draeger X-zone 5000 can be left in situ for up to 120 hours continuous operation, issuing an alarm as long as the danger exists. For further information contact Customer Service, Draeger Safety UK Limited, Ullswater Close, Blyth Riverside Business Park, Blyth, Northumberland, NE24 4RG. Tel: 01670 561200, fax: 01670 356266, www.draeger.com

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INDUSTRY NEWS

SKF MICROLOG ADVISOR PRO PUTS ON-THESPOT EXPERT KNOWLEDGE IN YOUR HANDS The new SKF Microlog Adviser Pro gives maintenance, service and quality inspection technicians on-thespot and easy to understand machine condition diagnosis. This ‘standalone’ device does not rely on prior measurement data, and does not require advanced PdM software. As a result, users immediately benefit from a proactive maintenance approach without the need for vibration expertise, or prior setup of an advanced PdM route-based system. And with the ability to choose from a range of application modules, the SKF Microlog Advisor Pro delivers the functionality of several maintenance tools in one handheld device. Designed for use by expert and novice users alike, the Advisor Pro is ideal for service, maintenance, inspection, and diagnostic applications. This three-channel, portable maintenance tool is new to the SKF Microlog family of products. As such, it combines all of the features customers have come to expect from an SKF Microlog, combined with an intuitive user interface, simple wizard-driven measurement instructions, and an automated analysis system based on pre-programmed ISO standards. Green, yellow and red color-codes quickly and clearly indicate test status, invalid or abnormal measurements, and machinery condition. “The Microlog Adviser Pro puts a range of maintenance and diagnostic tasks in the hands of experts and non-experts alike,” said Paul Edwards, Product Manager, SKF. “The Advisor Pro is a productivity tool for service, maintenance and inspection teams, giving fast and easy to understand diagnosis, with the ability to expand the tool’s functionality as analysis needs change – without the need to purchase another instrument. But it’s not all about the specifications. We know our customers look at the bigger picture when investing in maintenance equipment. SKF Microlog has been, and remains at the leading edge of condition monitoring and vibration analysis technology. This pedigree gives our customers security, and with SKF, they

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get the confidence and peace of mind from working with one of the most respected and widely-used vibration data analysis and industrial global service brands in the world.” Ergonomically designed and easy to use, the Microlog Advisor Pro features an easy-to-read, 25,600-line resolution color display, an advanced computing engine, high-performance data acquisition hardware and DSP technology, and a 40 kHz Fmax. The unit also features extended battery life for up to eight hours of continuous use, as well as easy memory upgrades via SD card. If required, data can be output for further analysis and report generation. In addition, a range of pre-configured, application-specific kits are available that provide users with all associated accessories and sensors, as well as modules such as Spindle Assessment and Idler Sound Monitor. The SKF Microlog Advisor Pro also can be provided with a PCbased Analysis and Reporting module. Once data is uploaded to this module, it is automatically shown in the application main window, and a single mouse click is all that is needed to view the data in a powerful, interactive graphical plot. The Analysis and Reporting Module also provides a range of postprocessing features that allow you to get the most out of your SKF Microlog Advisor Pro data. Additionally, a full range of Microlog accessories are available. Further enhancing the flexibility of the Microlog Advisor Pro, a range of application modules are available, allowing users to create a custom device that suits their individual requirements. Modules can be added as a user’s needs develop, increasing the value of the hardware investment by upgrading capabilities without the need to buy a new instrument. Application modules include Balancing; Bump Analysis; Recorder; Frequency Response Function; Run up/Coast down and Check to Conformance. This range of application modules allows users to perform several advanced tasks – such as impact tests, digital recording, modal analysis, transient phenomena analysis and quality inspections – all with the same device.

Visit www.skf.com/cm/microlog for more information on SKF Microlog Advisor Pro.


INDUSTRY NEWS

MAKING A POSITIVE ID Monitran Adds ‘1Y Smart Sensors’ To Its Mtn/2200 Range Of Vibration Transducers Southern Manufacturing, Farnborough, United Kingdom - Monitran, a worldleader in the development and manufacture of transducers for the measurement of vibration, displacement and proximity, has added ‘smart sensors’ to its MTN/2200 product range. The new sensors, which carry the postfix ‘1Y’ to their current part numbers, conform to IEEE-P1451.4 (Transducer Electronic Data Sheet, or TEDS) and can be interrogated by reversing the polarity of their supply voltage. Typical data that can be programmed and read back include the manufacturer’s ID, device part number, serial number, sensitivity (as set by the OEM) and calibration data. Donald Lyon, Managing Director of Monitran, comments: “These sensors are ideal for applications where multiple sensors are in use, and where measurements are typically collected in one place. In such circumstances, the rapid, positive and unique identification of sensors is essential.” Devices in the new 22001Y range are ideal for vibration analysis. As standard they operate between ±80g, have a rapid response to shock loading and can withstand forces in excess of 10,000g. They have isolated AC outputs with standard sensitivities of 100mV/g and alternative sensitivities are available upon request. In addition, they have good bias voltage stability with typical drift less than 3mV/oC with a bias voltage of 11.6V. All sensors in the new ranges are available as top- or sideentry and with integral cables or connectors. Submersible and intrinsically safe versions are also available.

Above: Monitran adds ‘1Y smart sensors’ to its MTN/2200 range of vibration transducers.

About Monitran Established in 1986 and based near High Wycombe in the UK, Monitran is a world leader in the development and manufacture of sensors and systems for vibration and displacement measurement. The company has the widest range of standard vibration and displacement products available from any single supplier and has an impressive track record of customising products for bespoke applications. With full ISO 9001:2008 approval, Monitran’s products are used for monitoring vibrations in machinery (such as pumps, motors, engines and drive trains) in a diverse range of applications including automotive, aerospace, industrial processing, power stations and wind turbines. Indeed, the products are at home in any application where vibrations or displacements provide early indications of mechanical wear or that a structure’s integrity has been compromised. They are also used in other vibration related applications, such as R&D, structural testing, equipment qualification testing and calibration.

Products are available immediately and interested parties should contact Monitran directly on +44 (0)1494 816569 or info@monitran.com.

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MAINTEC REVIEW

WITH THE HELP OF EMS PROMOTION, MAINTEC 2011 ATTRACTS RECORD CROWDS MAINTEC 2011 at the NEC was a huge success yet again this year, as a record number of visitors turned out in force to investigate the very latest advances in asset management and maintenance technology. The industry’s leading event, held on 29th, 30th and 31st March, attracted 1,726 unique visitors/buyers to Birmingham’s NEC – a rise of nearly 6% on last year. With an additional 512 professionals in the halls manning their stands, this time-and-cost effective platform is a proven place for business, confirmed by the record rebooking rate. A huge 68% of exhibitors rebooked on-site for the 2012 event, which takes place on 28th February 2012 – 1st March 2012. easyFairs UK, Managing Director Matt Benyon comments: “The 2011 Maintec event was our busiest yet – we always measure success on the quality and number of visitors and this show undoubtedly brought in both. Over the three days we attracted major key decision makers from the maintenance and engineering sectors creating fantastic opportunities for our exhibitors. However, the true measure is in the number of satisfied exhibitors and we are delighted that over two thirds have already signed contracts to exhibit again next year.” Exhibitor, Andy Baker, UK and Ireland Sales Manager at FLIR Systems said: “As a longstanding exhibitor at Maintec we really noticed a big difference this year. We received a third more leads than in 2010 and their quality was excellent. Before the show FLIR had launched a brand new mid-range of thermal imaging cameras and we were delighted that the many stand visitors made the trip to Maintec to see and then order these new models. Great result for us.” “I agree,” said James Miller, from Dust Control, who were also exhibiting. “There’s nothing better than being able to demonstrate your products face-to-face, especially when the person you are demonstrating the product to is the key decision maker. We met a great selection of potential new customers from a broad base, which is important to us. It is good to have a forum where we can talk seriously to relevant people from companies such as Nestle, BAE Systems and Royal Mail and know that we have products to suit them and help in their processes. MAINTEC is a great marketing tool that allows us to demonstrate products to the right people and is an ideal way to promote our company.” The show also proved popular to first time exhibitors, as Lesley Rigg, Business Development Manager at Safety Pass Alliance (SPA) explained: “We deliberately chose the easyFairs® MAINTEC 2011 to launch our new facilities management health & safety ‘passport’ (for contractors visiting customers’ premises) and were very pleased that we did. It was our first time at Maintec and we had some excellent quality leads, of which we hope to convert at least 50 per cent. The event was well organised, all the stands were taken and the staff were very helpful.” Visiting the show was Cecilia Pearce, Owner of Telecetera who commented: “Businesses are working hard to get the economy back on track, and MAINTEC was a real display of this. Communicating with other businesses really re-enforced my conviction that great things are to come in British industry. I managed to meet a lot of people, make some connections and learn about what is out there. It was great to see an event on this scale.” The show included a comprehensive ‘free to attend’ learnShopTM seminar programme, with speakers from Siemens plc, Fluke UK, Panasonic EU, and The British Compressed Air Society. During the second day, and new to Maintec, the Dragons’ Den-inspired contest ‘Lions’ Lair’ took place, with the Siveco Group coming out on top winning the competition with their new M.tv product, which was described as the collaborative knowhow website for nomadic engineers & technicians. Matt Benyon concludes: “Year on year MAINTEC just keeps getting better and better. We’ll continue to represent the wider industry and add new show features to keep the buzz alive, already I’m looking forward to next year’s show.”

Stand bookings for MAINTEC 2012 which takes place on the 28th February 2012 – 1st March 2012 at the NEC, Birmingham can be made by contacting Lucy Daley on: 020 8843 8808 or email lucy.daley@easyFairs.com. For any further information please visit http://www.easyfairs.com/ maintecuk

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engineeringmaintenance.info March/April 2011


MAINTEC REVIEW

THERMAL ENERGY RECEIVES PURCHASE ORDER FROM SALISBURY DISTRICT HOSPITAL IN ENGLAND Thermal Energy International has announced that it received a purchase order for £246,000 from Salisbury District Hospital Trust to install a CHP exhaust stack condensing heat recovery system for use on its heating and hot water system. The system makes substantial economic and environmental savings by recovering large amounts of lost heat and energy from the boiler exhaust.

“This project will provide further energy savings to add to the energy efficiency of the CHP system to be installed concurrently and overall the carbon reduction expected from these projects will demonstrate a high commitment by the Trust to improving the environment” commented George Atkinson Head of Estates.

OPTRIS PI - THE MOST PORTABLE INFRARED CAMERA The optris PI allows measurements from -20 to 900°C with USB 2.0 interface for real time thermography and infrared video recording with a 120 Hz frame rate. It has a very small, water proof and rugged camera sensing head with exchangeable optics of 23°, 6° and 48°.

With dimensions of 45 mm x 45 mm x 62 mm and a weight of 250g it fits in narrow spaces, ideal for the use inside machines and test stations. The extensive software package optris PI connect includes a recording function for radiometric videos, snapshots, analysis and post processing of images or videos and a line scan mode.

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MAINTEC REVIEW

COUPLINGS

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engineeringmaintenance.info March/April 2011


INDUSTRY NEWS

SOUTHCO PLUGS THE LEAKS AND RELIEVES THE PRESSURE FOR AIR HANDLING SYSTEMS When seeking to increase the energy and operational efficiencies of its HVAC enclosures by eliminating air leakage through the latching systems, air conditioning equipment manufacturer Air Handling Systems Ltd. (AHS) looked to Southco – as the only company with a product which satisfied rigid pressure tests - to provide the solution. Shildon-based AHS manufactures bespoke air handling equipment – primarily HVAC enclosures – for the private and public sectors that include the hospital, pharmaceutical and automotive industries. Customers include organisations such as Bombardier, the BBC, various NHS Trusts and, more recently, Great Ormond Street Hospital. Within the air conditioning sector, energy efficiency and optimised operational performance have become industry requirements, particularly in service buildings such as hospitals where the demands for hygiene and comfort are high whilst at the same time there is an increasing emphasis on cost savings and reduction in waste. Air conditioning users are faced with having equipment in place that complies with Part L Building Regulations and provides cost savings through energy-efficient installations. There is an ongoing issue around air leakage from HVAC enclosures. Air leakage implies lost energy and increased cost. To counteract this, it is imperative to make the equipment as air tight as possible. The current industry standard is DW 143 Class B 1000 Pascal. When AHS pressure tested its air handling units, it found that the major cause of air leakage was via the sealing of the enclosure doors. Primarily, this was because the latches available at the time failed to properly engage and provide sufficient compression to seal the gasket on the thick door of the cabinets. This is when AHS turned to Southco, who it had been working with for many years as a dynamic, industry-leading company which shared its own innovative thinking and pioneering approach.

Wes Campbell, Technical Director at AHS: “Southco offered the perfect solution through modifying its standard E3 Vise Action compression latch and having additional thread for allowing the engagement of the nut at the rear of the latch, thereby accommodating tight compression for up to 50mm thick doors. Ulrike Sturman of Southco explains: “The Vise Action’ design of Southco’s E3 latch series has proved itself in millions of installations and continues to be a market-leading product for quick, secure closure in applications where vibration, sealing and quality are paramount. Its smooth operation aligns the pawl behind the frame and draws it up tight with a single continuous half-turn motion. Its compression action provides consistent 6.4 mm (.25”) pull-up for environmental sealing in gasketed applications, and helps reduce or eliminate noise and rattles caused by vibration. Over-centre latching resists accidental opening due to shock or vibration. The original Southco Vise Action mechanism combines with numerous body and head styles, designed to suit specific installation and application requirements.” AHS strives to outperform its competitors by applying very strict air leakage tests to its equipment. Whilst the industry standard is Leakage Class B 1000 Pascal, AHS equipment achieves Leakage Class C 1500 Pascal as a minimum. However, for some applications, it has reached Leakage Class D 2500 Pascal. Subject to the same rigid test conditions, the Southco E3 compression latch has successfully passed this same Class D rating. Wes Campbell of AHS concludes: “At Air Handling Systems we are very pleased to work with Southco and appreciate how accommodating Southco has been in finding the perfect solution to our problem.”

Southco Europe Ltd; Touch Point, Wainwright Road, Warndon, Worcester, WR4 9FA, UK Tel: +44 (0)1905 346500 Fax: +44 (0)1905 346501

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INDUSTRY NEWS

PANASONIC IEC61131 PLC PROGRAMMING SOFTWARE – CONTROL FPWIN-PRO VER6 •

Free demo disk offer – see below for further details Control FPWIN-Pro is the Panasonic programming software developed according to the international standard IEC 611313. This latest version is a result of experience gained over many years of program development. We were one of the first PLC manufacturers to offer an IEC 61131-3 programming software, and we are a leading member of the international organisation PLCopen.

• • • • •

• • Important features at a glance: • One software for all Panasonic FP Series PLCs • 5 programming languages (Instruction List, Ladder Diagram, Function Block Diagram, Sequential Function Chart, Structured Text)

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Well structured navigator provides effective overview of programming organization units (POUs), tasks, system registers, etc., simplifying project management Reuse of ready made functions and function blocks saves time for programming and debugging Programming, service, monitoring and diagnostics via RS232 (COM), Modem, Ethernet, USB Forced ON/OFF of input and output contacts via the PC Extensive comments - online documentation created hand in hand with the program The name of variables, functions, function blocks and comments can be written in all languages thanks to Unicode Improved programming comfort: snap function, automatic placement of newly inserted elements, existing connection retained while moving elements Keyboard-control mode can accelerate programming 6 languages are supported: English, German, French, Italian, Spanish and Japanese For more details or to request a free demo disk please contact Panasonic Electric Works UK Ltd on: 01908 231 555 or email info-uk@eu.pewg.panasonic.com


ENERGY MANAGEMENT

GLOBAL PHARMACEUTICAL COMPANY ACHIEVES ENERGY SAVINGS WITH GEM® A leading global healthcare company dealing with bioscience, medication delivery and renal products has revealed that it is saving over £36,000 a year in energy costs following the installation of Thermal Energy International’s GEM® steam traps at one of its facilities. Thermal Energy International has installed a total of 85 steam traps throughout the process plant achieving a 20% energy saving in just 18 months.

Having successfully installed GEM® Venturi steam traps at another of its European sites, the company asked Thermal Energy International to conduct a survey of its mechanical traps, which were regularly failing open, partly open and closed. The report from Thermal Energy International showed that

approximately 20% of the steamtraps on the site were failing open resulting in 7,568 of tonnes of steam being lost each year at a cost of £36,000. Not only was this increasing energy and maintenance costs, but it was also reducing production time and having an environmental impact by creating 1,067 tonnes of CO2 emissions each year. Thermal Energy International explained that by replacing the existing traps with the GEM® venturi orifice design, blocked steam traps could be prevented from impacting on production, and by efficiently returning condensate back to the boilers energy savings would be achieved. During the following 12-months all 85 mechanical traps were replaced with appropriately sized GEM® steam traps. Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the highly efficient GEM® steam traps use the venturi orifice design to effectively drain condensate from the steam system. As the GEM® steam traps have no moving parts to wedge open or fail, it provides the ultimate in reliability necessitating only minimal maintenance and requiring no spares, testing or monitoring equipment. Available in a wide range of sizes for a full cross section of applications, the hardwearing GEM® steam traps are manufactured from corrosion resistant stainless steel and are guaranteed for 10 years, obviating the need for repair or replacement. The GEM® steam traps provide a fast payback - on some processes within a matter of days - from reduced energy costs and increased equipment reliability due to a reduction in damaging condensate in steam systems. In addition it improves product processing by enhancing the quality of steam and also reduces equipment repairs, downtime and replacement costs.

Thermal Energy International Inc. 1 John Street, Bristol, BS1 2HR Tel: 0117 917 7010 Fax: 0117 917 7011 www.gemtrap.com

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INDUSTRY NEWS

TAKE CONTROL OF ALL YOUR PROCESSES WITH ABB’S NEW CONTROLMASTER RANGE Finding the right process controller has just got easier with the launch of ABB’s ControlMaster range. Building on the highly successful Commander family, the ControlMaster range now offers an even wider range of control and indicator functions in just four easy to specify versions.  A key feature of the CM15 indicator and the CM10, CM30 and CM50 controllers is their full colour TFT display, providing operators with a clear and comprehensive display of process status and key information. Adjustment of the display via the customisation feature enables the operator to tailor their view to their requirements, while a chart display provides short term trending information. The use of a TFT display also makes the ControlMaster range extremely easy to configure. Configuration menus are displayed in clear text, with no complex codes or abbreviations found on controllers with lesser displays. Further time savings during configuration are made possible by the use of built-in application templates, enabling operators to simply select the template best matched to their requirements, with the ControlMaster automatically configuring its I/O, display and control strategy to suit. Configuration can also be performed via DTM-based PC configuration software.   Configuration files can be transferred to the ControlMaster via its front-mounted infrared port or stored locally on a PC. The ControlMaster range offers a choice of communications options – Ethernet, Modbus, and Profibus. Ethernet communications provide the ability for users to be automatically notified of critical process events via email or remotely monitor the controller and process via the ControlMaster’s integrated webserver by simply using a standard web browser. For integration with larger control systems, the Modbus (RTU and TCP) and Profibus options enable access to real time data on process values and device status.

Other new features include additional control options alongside the standard cascade, ratio and feedforward control functions to help bring even the trickiest processes under control.  Predictive control algorithms including dead time compensation, makes the ControlMaster ideal for applications with long dead-times such as pH dosing applications. Added control efficiency is enabled by the inclusion of adaptive control, which allows the ControlMaster to automatically adjust its control response to suit variations in process response. Dual loop control makes it possible to use one ControlMaster to control two processes.  The inclusion of additional auto tuner, math, logic, gain scheduling, totalizer, custom lineariser and delay timer functions provide powerful problem-solving functionality. With just four models in the range, product selection for basic through to advanced applications has never been easier.  Initial model selection is made based on panel cut-out and then I/O and control functionality selected to suit application requirements.  When required field upgrades can be easily performed using plug and play function keys and I/O cards.  The common design of all of the four models provides standard operation and configuration across the range. All products in the ControlMaster range feature full IP66 and NEMA4X protection as standard. These high levels of protection makes the range suitable for a wide range of industrial control applications, from arduous oil and gas facilities through to the washdown environments in the food and beverage industry. The ControlMaster range is now available from ABB and its ABB Instrumentation Alliance Partner network.

For more information: Please email: moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘ControlMaster’.

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STEAM SYSTEMS

BOOST YOUR BOTTOM LINE WITH THE HIGHEST STANDARD OF STEAM SYSTEM SERVICE It can be a challenge to keep steam systems performing at their best when they’re not your core business and highly-trained engineers are hard to come by. Rob King, Services Sales Manager at Spirax Sarco suggests that outsourcing is the answer. Steam users can often find it hard to dedicate the time and in-house resources to establish comprehensive planned maintenance, particularly on specialised process plant. Outsourcing some or all of the on-going maintenance work to steam system specialists, like Spirax Sarco, allows organisations to benefit from a level of experience and knowhow that they’re unlikely to have access to otherwise. Steam experts can apply the latest best practice to help identify, design and implement improvements and then maintain the resulting efficiency gains. Outsourcing the management of such a vital utility demands a high level of co-operation and trust between the customer and the supplier, so choosing the right managed service partner is critical. It makes sense for steam users to opt for a well established equipment and services provider that has already built a successful business thanks to a track record of delivering on its promises. There are many possibilities in terms of the type and scale of services that can be outsourced successfully. Users may be looking to boost the performance of an existing system or build a new installation from scratch, for instance. They may want help or advice on managing a single heat exchanger, or they may want a partner to manage the entire steam distribution system and keep it working at peak performance for years to come. The right technology provider should offer a flexible portfolio of options to fit each steam user’s circumstances and budget.

Big Rewards The potential benefits can be loosely divided into four categories: First, users can beat rising costs and enjoy lower fuel bills through improved energy efficiency. This is often complemented by substantial savings in water, chemical treatment, effluent and manpower costs. Next, outsourcing can ease the pressure on hard-pressed in-house maintenance teams. Not only is much of the maintenance work carried out by external specialists, but the steam system should be more reliable thanks to regular plant assessments and well-managed plant documentation. This will release valuable manpower for other maintenance duties. A reliable supply of good quality steam at the right temperature and pressure helps to ensure maximum productivity in process applications, so the operation as a whole should perform better. Last but certainly not least, effective steam system management will help safeguard personnel and other assets. Ensuring that the system complies with safety requirements and using best working practices reduces business risks and improves personnel safety.

From assessment to follow-up Any outsourcing process for steam systems will start with a survey. This provides an in-depth assessment of the system’s current state of efficiency and identifies areas for improvement. Engineers can then highlight ways in which savings can be made and calculate the potential return on investment. Surveys can range from a full steam system survey to a steam trap or boiler house survey. The service partners will typically review the survey report’s recommendations together and the steam user will then decide which measures provide the best fit with their business objectives. These recommendations might include investing in new equipment, but surveys often highlight low-cost measures that can deliver significant benefits, such as adopting best

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STEAM SYSTEMS

practice. The service provider then plans, costs and can even execute a programme of work to set the system on track towards its maximum efficiency. Having invested in a steam system by bringing it up to its peak operating efficiency, it makes economic sense to maintain it at that level. This is where outsourcing the maintenance and service work offers a really cost-effective solution. Cover can extend beyond breakdowns to include preventive maintenance, which promotes uninterrupted plant operations at the highest levels of performance. Again, the ideal service partner will offer a range of options to suit the steam user’s needs and budget. For example, Spirax Sarco’s standard options for service agreements can cover anything from the full boiler house to steam traps or even individual items of equipment. Of course, it’s not just the hardware that needs to be right. The correct water treatment is also essential for high-quality steam. Many suppliers of water treatment chemicals focus solely on the boiler, but the quality of the steam and condensate throughout the system is just as important for long-term performance. Water conditioning must optimise the overall efficiency of the entire steam and condensate handling circuit. Adopting a whole-system approach to water treatment reduces energy consumption, cuts maintenance costs and minimises downtime. All conditioning work should comply with the relevant British Standards and FDA guidelines for water treatment. Outsourcing can be a great option for steam users. Spirax Sarco knows from experience that customers typically enjoy greater energy efficiency, improved productivity and lower costs over the lifetime of their steam systems as a result, whatever their core business. Spirax Sarco’s extensive range of services can boost the efficiency of existing steam systems or, bespoke designs for new builds can be managed from start to finish. Ensure your steam system is in optimum condition by contacting Spirax Sarco’s Services Team on 01242 535390 or email services@uk.spiraxsarco.com.

Training provides the winning formula Proper training for boiler operators increases plant safety, cuts energy costs and benefits a company’s bottom line. Getting the most from advanced steam systems demands well-trained plant operators who are not always easy to find. Many companies find it increasingly difficult to recruit skilled engineering staff. Providing training to bring people up to standard is a good solution, and outsourcing to a trusted training provider offers companies access to specialised facilities, properly structured courses and highly-qualified instructors. The “gold standard” for boiler operator training is BOAS (the Boiler Operative Accreditation Scheme), which was launched in 2005 by the Combustion Engineering Association (CEA). The scheme is operated in conjunction with Gastec, which acts as an independent assessor. Spirax Sarco is an accredited BOAS provider, as well as running courses that are approved by professional bodies such as the Chartered Institute of Building Services Engineers, BTEC and City & Guilds. The benefits of training include improved health and safety and energy efficiency, but well-trained personnel also impact positively on the bottom line. For example, a report from the Advanced Institute of Management Research suggests that a five per cent rise in skills among staff typically leads to a four per cent rise in productivity. With this in mind, Spirax Sarco runs a course designed to make engineers aware of how they could be saving money in their steam systems. It gives delegates the skills they need to make a real impact on energy bills. So if you’re asking yourself whether your organisation can afford to invest in steam system training you’re asking the wrong question. The real question is whether you can afford not to. For a free copy of the 2011 Spirax Sarco Steam System Training Brochure or to enquire about any of your training needs, please contact Spirax Sarco’s Training Coordinator on 01242 535211 or email training.centre@ uk.spiraxsarco.com.

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COMPRESSED AIR

BEKO TECHNOLOGIES FOR “BIG AIR” The setting up of BEKO Systems was important to the BEKO group because it gave the company capability in very large dryers up to 20,000m³ /hr. The product range which is the “EVERDRY” range of heat regenerated adsorption dryers goes to the 20,000 m³ /hr stated but the company has the capability to provide solutions tailor made to customers’ needs beyond this figure. Drying compressed air to low dew points such as -40ºC is expensive. The desiccant medium has to go through a regeneration process in order to drive off the water adsorbed but then must be cooled down before the desiccant can start drying again. The industry standard of course is that a desiccant dryer is 2 columns filled with desiccant. The first column dries the compressed air until the desiccant is partly saturated then the other column comes on line and the wet column is regenerated and cooled. All this takes energy and hence the trend has been, in these more energy conscious times, away from any kind of purge loss of the compressed air. In fact the ultimate solution to reduce drying costs is the HOC, heat of compression dryer. This type of dryer uses the fact that compressing air raises the temperature of the air in 2 stage non lubricated compressors to approaching 200ºC. In all other drying solutions this heat is allowed to pass downstream where it can be recovered and used but in many cases goes to waste through the cooling system. Heat of Compression Dryer layout This type of dryer is gaining increased market share because it can offer low dew points and also low running costs. Different types of compressors require different versions of HOC Adsorption dryers. The standard range of BEKO fulfils all these various requirements. The version EVERDRY HOC-R (reload) provides stable pressure dew points lower than -40ºC. Even the demand for high quality air of the electronic industry with pressure dew points of -70 ºC will be realised with the Reload procedure. The range includes 3 other ranges of the classic twin column or tower heat reactivated adsorption dryers FRP Range of Heat Regenerated Adsorption Dryers

FRA Range of Heat Regenerated Adsorption Dryers

FRP dryer layout

Uses heated blower air to regenerate the desiccant, cooling

Uses heated blower air to regenerate the desiccant and a

is by ambient air and a blower

small purge flow of expanded dry air to cool the desiccant. This product with fewer components is to satisfy the needs of customers who need to keep the capital costs down to a minimum. Performance range 580-40,000 m³/hr Dew point to -40ºC at pressure

FRA dryer layout Performance range 580-40,000 m³/hr Dew point to -40ºC at pressure Suitable for moderate climate zones

All climate zones FRL Range of Heat Regenerated Adsorption Dryers The FRL dryer is aimed at critical ambient conditions, normally high temperatures and includes a closed circuit loop for cooling using blower air and of course the regeneration by heated blower air. FRL Dryer layout Performance range 580-40,000 m³/hr Dew point to -70ºC at pressure Suitable for all climate zones The FRA and FRL Ranges are available in with a reversible blower for cooling the desiccant with the benefit of fewer moving parts. The above products together with the DRYPOINT RA range of fridge dryers, the DRYPOINT M range of Membrane dryers and the standard DRYPOINT AC heatless desiccant range complete BEKO’s offering of “drying solutions”.

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BEKO Technologies Ltd Tel: +44 (0) 1527 575778 www.bekotechnologies.com


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COMPRESSED AIR

EFFECTIVE FILTRATION IS THE KEY TO R E D UCED CO S T O F O W N E R S HI P Richard Moore, at Parker Hannifin’s domnick hunter Industrial Division, looks at the importance of selecting compressed air filtration for both air quality and lifetime operating cost, rather than just initial purchase cost. Compressed air is widely used throughout industry, so much so that it is often regarded as the fourth utility. However, unlike electricity, gas and water, it is unique in that it is generated onsite rather than being delivered by an external service provider. Ultimately, this creates a situation where the quality of compressed air and the costs associated with its generation and subsequent use are solely in the hands of the user, including the level of contamination removal.

With companies across industry coming under increasing pressure to minimise costs, a reduction in both energy consumption, through lower compressed air usage, and effective, planned maintenance can play a vital role in protecting operating margins. Effective filtration is key to the efficient operation of all compressed air systems. To be truly cost effective, however, filtration must be proactively planned and managed as part of an ongoing maintenance strategy, and be properly costed; this means looking beyond the initial purchase price of each element to the total lifetime operating cost. To realise the full capacity of a modern industrial plant, compressed air quality must be kept consistent using correctly specified, installed and maintained filtration technologies to remove oil and water, airborne particulate, rust and pipescale, micro organisms and oil vapour. Filter elements form the heart of every compressed air system. However, by their very nature, the filter element and housing restrict the flow of compressed air, thus reducing the available system pressure downstream and affecting the energy consumption of the filter. This system pressure reduction, often known as pressure loss, is typically measured between the inlet and outlet of the purification equipment, and recorded as a pressure drop or differential pressure. As compressors generally require large amounts of electrical energy to produce a volume of compressed air at a given pressure, these pressure losses will be converted directly into energy losses and consequently to operational costs for the user. Furthermore, production machinery or processes typically require a fixed volume of compressed air, delivered within a predetermined pressure range to function correctly. Therefore, to overcome filter and other pressure losses in the system, compressors are often operated at greater pressures than would normally be required by the application, increasing compressor operating costs still further. These pressure losses across a filter fall into one of two categories – fixed or incremental pressure losses. Fixed pressure losses are a direct result of the filter housing design and the element fit or interface, with a poorly designed filter housing and element interface creating a greater resistance to airflow and producing a higher differential pressure, which translates to increased operational costs. Incremental pressure losses stem from the filter element itself and increase as the element collects more contaminants, however, incremental losses are often variable, depending on the filtration media used, the method of construction and its ability to remove and retain contamination. Total pressure losses are a combination of fixed and

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COMPRESSED AIR incremental losses; so if fixed losses are high as a result of poor design, then the incremental losses will add to the already elevated operational costs of the filter.

the sole reason to change filter elements must always be to maintain air quality and therefore it is always wise to follow the manufacturer’s recommendations if this is to be achieved. Why compromise air quality for the cost of a filter element?

Accordingly, in a bid to put a cap on operational costs, companies generally base the decision to replace elements on the pressure drop measured across each filter. However, what often is forgotten is that the fundamental function of the filter is to improve air quality by removing contamination. In practice, the ability of an element to remove contamination may well have fallen to a critical level long before the point at which the pressure drop indicates an element change may be required. Perhaps most importantly, it is vital that highly specialised filtration materials are used in order to achieve the stringent air quality levels required both by modern industry and ISO8573-1, the international standard for compressed air quality. Yet, regardless of which materials are employed, the filter media in coalescing and dust removal filters is constantly bombarded by high velocity dirt particles, while also having to withstand extremes of pressure, temperature and a variable air demand throughout their operating life. In addition, coalescing filters also have to contend with being submersed in acidic condensate, including oil and chemical additives from compressor lubricants, as well as hot water.

About Parker Hannifin With annual sales of $10 billion in fiscal year 2010, Parker Hannifin is the world’s

As a result, all filtration media has both a finite life and capacity to retain contamination and once spent the required air quality can no longer be maintained. Therefore, considering that filters are installed to provide contaminant removal to a specific air quality requirement, the sole reason to replace filter elements should always be to maintain air quality and not simply because of a pressure drop across the filter.

leading diversified manufacturer of

However, pressure losses in some systems can still cause significant problems, particularly in heavily contaminated installations where excessive pressure losses may result in the shut down of production processes. In these instances, filter elements should be changed according to the manufacturer’s recommendations to maintain air quality unless unacceptable pressure losses result.

industrial and aerospace markets.

Many modern filter housings are fitted with differential pressure gauges, which measure the difference in pressure between the air entering and exiting the filter. It is important to remember, however, that these are not service indicators, do not provide a measurement of air quality, are generally not precise and offer no level of calibration. Often, these gauges have areas of green and red, which misleadingly can indicate that the element does not require replacement if the needle is in the green.

annual dividends paid to shareholders

For example, as the media in the filter element degrades, even a tiny hole the size of a pin point can result in the filter media rupturing, allowing all contamination to be carried past the filter and into the compressed air system. Should this occur, the gauge needle would remain in the green area and the filter element would not be serviced until the user eventually detected contamination downstream. Even when the filter element is replaced after such an incident, contamination would still be present downstream for some time. Considering the importance of system performance and reliability, it is important to analyse the cost of filter element replacement against the cost of not replacing them, taking into account the risk of damaged equipment, increased downtime, emergency repair costs and contaminated or faulty product batches. What sometimes seems like a cost saving in the short term can turn out to be a costly mistake. Ultimately then,

motion and control technologies and systems, providing precision-engineered solutions for a wide variety of mobile, The company employs approximately 55,000 people in 46 countries around the world. Parker has increased its for 54 consecutive years, among the top five longest-running dividend-increase records in the S&P 500 index.

For more information, visit the company’s web site at http://www.parker.com, or its investor information site at http://www.phstock.com. Please send all sales enquiries to: Parker Hannifin Ltd, domnick hunter Industrial Division Dukesway, Team Valley Trading Estate, Gateshead, Tyne & Wear, NE11 0PZ, England. Phone +44 (0)191 402 9000, Fax +44 (0) 191 482 6296

Email: dhindsales@parker.com

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COMPRESSED AIR

MOTIVAIR LAUNCHES CLEANEST AIR COMPRESSOR IN THE INDUSTRY MARCH 2011 Motivair, the UK’s leading independent provider of compressed air services, has today announced the launch of Opus Crystal, a revolutionary new compressor package which uses innovative catalytic technology to deliver crystal clear air - simply, efficiently and economically. Opus Crystal combines traditional compressor technologies with a bespoke catalytic system that is designed to remove all impurities from the atmosphere, including minuscule hydrocarbon particles. This makes it the perfect solution for industries such as food manufacture, hospitals, dentists, pharmaceutical, spray finishing and anywhere else where pollutant-free air is essential. The technology, tested by the renowned German safety agency, TÜV, means that the Opus Crystal has been certified

as producing air which is well within the limits for class zero to ISO8573.1:2010. Furthermore, the condensate is so clean it can be disposed of straight down a foul sewer. As an evolution to the traditional ‘oil-free’ systems currently available in the UK, Opus Crystal actually deals with the issue of how clean the air is at the point of intake. Using catalytic material heated to +200°C, the unit chemically converts harmful hydrocarbons into harmless water and carbon dioxide, capturing all other unwanted molecules in the catalyst.

support@motivair.co.uk www.motivair.co.uk

INDUSTRY NEWS

ERIKS INTEGRATED SOLUTIONS WINS MULTI-MILLION CONTRACT FROM BRITISH GYPSUM ERIKS Integrated Solutions, part of ERIKS UK, has won a major multi-million pound contract from British Gypsum, the leading UK manufacturer and supplier of gypsum based plastering and drylining solutions. The contract is for the provision of dedicated procurement, inventory control and stores management services at five production sites across the UK, and will help British Gypsum improve still further the efficiency and productivity of its operation, while reducing both waste and cost. British Gypsum supplies a wide range of specialised building products that are used throughout the construction industry, in residential, commercial and public sector buildings. Central to the continued success of the company’s business is its long term World Class Manufacturing programme. This sets out to achieve the highest possible standards of product quality, delivery and customer support, with the best employee safety and working conditions, minimum energy consumption and waste, and optimum cost control. Martin Stainton, Commercial Director of ERIKS Integrated Solutions, explains, “We’ve been partnering with British Gypsum since 2003 and this new five year contract extends our relationship still further. Through the on-site management

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of British Gypsum’s procurement, inventory and stores systems our directly employed team has built up extensive knowledge of the company’s World Class Manufacturing initiative, enabling us to add real value in the drive to improve efficiency and control operating costs.” For further information, please contact: Robyn Bradley, Marketing Executive, ERIKS UK. T: +44 (0)121 508 6219. M: +44(0)7740 452743 robyn.bradley@eriks.co.uk


PRODUCT SPOTLIGHT – CHEMICAL CLEANING

SABSCO IS A UK BASED INDUSTRIAL SERVICES COMPANY

SPECIALISING IN STEAM AND AIR BLOWING AND CHEMICAL CLEANING.

SABSCO is part of the Solarca group of companies with the head office based in Spain. The Solarca group has offices throughout the world ensuring that we can service jobs quickly and efficiently whilst having the technical backup and expertise from the individual specialist companies. SABSCO/Solarca’s wide experience and knowledge of the industrial sector allows us to offer a wide range of chemical cleaning services to our clients. These services include:•

Chemical Cleaning Maintenance

Online Furnace Cleaning

Preoperational Descaling

One Phase Cleaning

Steam and Air Blowing

David Cooper Commercial Manager david.cooper@sabsco.com Enterprise House Norfolk Road Gravesend Kent DA12 2ps Tel. (+44) 1474 333366

PRODUCT SPOTLIGHT – CHEMICAL CLEANING

CHEMICAL CLEANING Can be the most efficient, costeffective method for cleaning sensitive contaminated surfaces or areas that are only accessible by flow.

PowerFal prioritizes safety and attention to detail, while determining the most appropriate technique based on our extensive experience. Our capabilities include but are not limited to: Boilers

Passivation Processes

Heat transfer Systems

Heat Exchangers

Turbine, hydraulic oil systems

Degreasing

Condensers

Cooling Systems

Process Piping Systems

Refrigeration System Cleaning

Pickling Process

Tank and vessel cleaning

Widely used in the power generation, marine propulsion and manufacturing industries, chemical cleaning is ideal for applications where thorough cleaning through dismantling procedures are impractical. Our first step in any project is a complete, comprehensive analysis.

Where necessary we will: •

Obtain samples to be tested ensuring the correct chemical is applied.

Inspect and if necessary remove key components for

Before

cleaning.

For More Details

Remove associated pipe work.

All components and associated pipe work can be

Tel 01326377160

transported to our works for specialized cleaning.

After Fax 01326377161

www.powerfal.co.uk

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FATIGUE TESTING EQUIPMENT

ONLINE CONDITION MONITORING SYSTEMS

EXTEND FLUID SYSTEM LIFE QUICKLY AND COST EFFECTIVELY WITH PARKER PARTICLE DETECTOR A new online detector, developed by Parker Hannifin, the global leader in motion and control technologies, has been introduced to help cut the cost of maintenance, repair and overhaul of hydraulic fluid systems by providing continuous monitoring and early warning of particle contamination. Called the iCountPD, this compact device is a particularly simple to install and easy to use solution for maximising the productivity and extending the operating life of equipment in many industrial applications. Using innovative laser particle and moisture detection technology, this new instrument produces repeatable and ultra accurate results, and is calibrated to international standards. Users are alerted to low, medium and high contamination levels via an LED or digital display so that the necessary action can be taken quickly before system degradation or failure occurs.

Contact: John Botly, Marketing Services Manager Parker Filter Division Europe, Thetford Phone: 01842 763299 E-mail: john.botly@parker.com

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PRODUCT SPOTLIGHT – DEWPOINT HYGROMETER

HIGH-SPEED PORTABLE DEW-POINT METER Michell Instruments’ MDM300 Advanced DewPoint Hygrometer gives fast, accurate measurements – even to dew-points as low as -70°C. Reducing the waiting time gives you more measurements per day and more time to get on with your job. Convenient and practical to use: the MDM300 is easily held and operated at the same time – even with gloves. Its bright, back-lit display is readable in the dark enabling measurements to be made quickly whatever the conditions. ‘Plug and play’ – works straight from the box: with built-in datalogging as standard and an intuitive menu system, you can start to use the MDM300 right away without needing to spend

e: uk.info@michell.com t: 01353 658000

hours training staff to use it.

Your can also find out more by visiting pour website at:

Request a free, no obligation site survey of your compressed

www.michell.com/uk

air system and see the MDM300 at work.

COOL MEDICS PRODUCT STYLE #M1863 IS A HIGH VISIBILITY SAFETY VEST LIKE NO OTHER Cool Medics is a family owned company that has been in business in Southern California for more than 20 Years. They manufacture high quality personal cooling products right here in the United States of America, at their facility in Oceanside, California. Cool Medics product style #M1863 is a high visibility safety vest like no other. Not only does it provide all the High Visibility requirements of OSHA, but it also provides cooling properties for the wearer. Our vests work on an evaporative cooling technique once it has been activated in water. When the moisture in the fabric evaporates through the hydrophilic fibers, heat is removed which causes the surrounding area to cool down, transferring the cooling effect to the wearer. This process will cool the wearer down by 20 to 25 degrees, the effects of which can last anywhere from 4 ½ to 8 hours. This vest has a zipper front and open neckline. Adjustable back tabs of heavy elastic and hook and loop closures ensure a snug fit. Two rows of 2 inch reflective tape across the shoulders, front and the back of this vest make this a multipurpose cooling vest, as it converts into a safety-cooling vest, very visible during day and at night. This vest conforms to ANSI 107-2010 Class 2, and is available in sizes SM to 4XL in Safety Orange and Safety Yellow colors. It is also available as style #M1864 with attachable and detachable pockets.

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International Distributors Wanted!!! Please see our Cool Medics website for additional products at www.coolmedicspublicsafety.com or call us 760-966-0040 email: sales@coolmedicspublicsafety.com


PRODUCT SPOTLIGHT - CORROSION PROTECTION

ANTI-CORROSION PRODUCTS FROM DR. SHRINK Dr. Shrink, Inc. is a full service— full circle supplier of premium shrink wrap and all installation accessories. They are noted for innovative products, prompt delivery, competitive pricing and experienced application advice. For shrink wrapping of machinery, metal products, electrical boxes, etc. we have Volatile Corrosion Inhibiting (VCI) Shrink Wrap in a 20’ width, VCI Capsules that protect electrical boxes and circuitry, and Container Dri II bags, that collect some moisture under shrink wrap covers—and then lower relative humidity to keep condensation from forming. These products work well for protecting almost any item from weather damage while being transported or stored. All of our shrink wrap is 100% virgin resin material with maximum UV inhibitors for long term usage.

Please contact Dr. Shrink, Inc. with any questions or comments regarding our Anti-Corrosion products at 800.968.5147 or drshrink@dr-shrink.com. Visit us on the web: www.dr-shrink.com. PRODUCT SPOTLIGHT - DAMPERS & ACTUATORS

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PRODUCT SPOTLIGHT – HANDHELD PREDICTIVE MAINTENANCE

HOW DO YOU KNOW IF THINGS ARE OK OR NOT? Go and check them is the answer - but obviously you can’t do it all by yourself! C-Cubed’s new Pocket Inspection system allows absolutely anybody to do it for you by simply answering a list of user defined questions on a rugged handheld PC. The answers are stored and uploaded to a PC, automatically flagging up any warnings or alarms and sending out emails to anyone who needs to know! The Pocket Inspection unit is ultra-rugged with touchscreen and keypad entry capability. The software is incredibly easy to use with a set of “pre-canned” inspections that can easily be edited to create new inspections or simply make up your own. “Is the floor clean?”, “Are the lights working?” etc….

www.pocketvibra.com T: 01256 895 050 PRODUCT SPOTLIGHT – DATALOGGERS

NEW ENERGY LOGGER HELPS LOWER COSTS

Gemini Data Loggers has developed the Tinytag Energy Logger, which is a simple, safe tool for the non-invasive assessment of energy efficiency in

identification of power hungry equipment and processes.

both single and three phase power supplies.

Lightweight, portable and self-configuring, the Tinytag Energy Logger is extremely easy to use and does not require the exposure of any live wires or terminals so it is also very safe.

Designed for improved accuracy and ease of use, the instrument provides the level of performance required by experts with the level of simplicity required by energy management novices. Operation is deliberately easy; either as a hand-held unit for spot checks or as a data logger for longer term monitoring. Logging can be initiated by the touch of a button, so users do not need a laptop to operate the device onsite. Collected data provides a clear analysis of energy efficiency, enabling the rapid

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For further information, please contact: Joy Young Gemini Data Loggers (UK) Ltd. Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, United Kingdom Tel: +44 (0)1243 813000 Email info@tinytag.info www.geminidataloggers.com


PRODUCT SPOTLIGHT – DATALOGGERS

American Thermal Instruments’ USB option extends LOG-IC® temperature monitoring advantages to any point in your supply chain where investments in readers may not be feasible. The USB option offers numerous benefits: • • • • • • •

Access to temperature data without readers Easy data downloads using universal USB port on any PC Complete PDF reports immediately after plugging in datalogger Temperature monitoring at any point in the supply chain Immediate decision support and documentation via emailed PDF reports Ability to pinpoint precise location of temperature abuse Universal standards to simplify use and data sharing in global applications

The LOG-IC USB design ensures a thorough, cost-effective solution to reduce risk. • • • •

USB port embedded in LOG-IC Onboard HI/LO excursion notification Resealable pouch to protect USB Compact, lightweight package.

The fully featured LOG-IC software comes free with the USB option. Matty Toomb vice president of sales & marketing 2400 east river road, dayton, oh 45439 937.429.2114 x115 mtoomb@americanthermal.com americanthermal.com

PRODUCT SPOTLIGHT – DATALOGGERS

DATA LOGGING INTERNET MANAGEMENT APPLICATION ViaTelemetry is the technology arm of the Brulines Group plc; company that has close to 40,000 remote monitoring and data logging units throughout the UK, Central Europe and U.S. Built on our expertise ViaTelemetry provides an off the shelf, end-to-end platform. In addition to hardware which includes I/O for interfacing to the remote machine, logging and GPRS connectivity, ViaTelemetry specialises in management, central logging, alarming and display of collected information into an Internet based application to turn data collection into real value. With applications in water quality, gas and waste measurement, temperature and environmental monitoring and many others, the technology is well proven, industry grade, robust and a scalable solution to your data logging needs.

Contact details: Barry Lowe - Business Development Director ViaTelemetry, Amscreen House, Paragon Business Park, Chorley New Road, Horwich, Bolton, BL6 6HG Tel: 01204 664330

barry.lowe@viatelemetry.com

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PRODUCT SPOTLIGHT – COOLING TOWERS

NEW GENERATION OF POWER TRANSMISSION COUPLING EXTENDS JOHN CRANE’S POWER INDUSTRY OFFERING John Crane has launched a new power transmission coupling which builds on its history as a supplier to the power generation market. The new Metastream M Series ZMH flexible membrane coupling improves on the high levels of performance safety and reliability provided by John Crane’s existing ZMC coupling and is specifically intended for cooing tower installations. The corrosion-resistant ZMH has been designed to withstand the hostile environments typically found in cooling towers and to improve on the performance provided by its predecessor. Designed for infinite life, it has no wearing parts, requires no

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lubrication and so represents a genuine fit-and-forget solution. A composite fibre spacer piece makes the easy-to-install ZMH up to 80% lighter than alternative “all metal” designs.

More information can be found at http://www.johncrane.co.uk


PRODUCT SPOTLIGHT – HUMIDITY CALIBRATION

PRODUCT SPOTLIGHT – FLOWMETERS

INSPIRING FLOW SENSOR TECHNOLOGY

Sensirion CMOSens® flow sensor technology is most effective at the lowest flow rates. Based on a thermal principle, Sensirion’s liquid flow products benefit from digital microsensor technology which offers totally media isolated flow sensing down to nanolitres per minute. The SLG1430/ALS1600 family offer extremely sensitive and fast measurement of liquid flows down to nanolitres, with a typical repeatability of 1% of reading. Over pressure ratings of up to 350 bars are also available. All flow meters measure non-invasively with exceptionally short response times in the millisecond range. The integrated straight flow channels are made of 100% glass to ensure excellent chemical resistance and biocompatibility. The absence of any moving parts ensures maximum reliability. For hydrocarbon based liquids the SLQ-HC60 with its IP65 rating is an ideal choice for industrial process applications. It can also be used to detect clogging, leaks and bubbles. The 0-10V output signal corresponds to flow rates up to 100ml/ min.

Sensirion products are available in the UK from APC Hero. For more information on Sensirion products contact; John Kain APC Hero Phoenix House 2 Phoenix Park Eaton Socon St Neots, Cambs PE9 8EP Tel; 01480 226656 Fax; 01480 218752 johnk@apc-hero.co.uk www.apc-hero.co.uk

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PRODUCT SPOTLIGHT – DESCALING

SYSTEM DESCALER, FROM ARROW CLEANING AND HYGIENE SOLUTIONS has been specifically formulated for the rapid removal of scale, process soils, oxidisation and rust from both ferrous and most non-ferrous metals and alloys. A highly concentrated cleaner, its low foaming formulation is particularly useful when large scale descaling or high pressure washing is required, and it has been primarily developed for in-line descaling of boilers and condensor pipework, air conditioning systems and any water processing equipment e.g. chillers, coolers and heat exchangers. System Descaler can also be used as an oxidisation remover from ferrous metals, stainless steel and non-ferrous aluminum, brass, copper and their alloys; therefore its uses are not limited to equipment, as it may also be used for restoring components in electrical products to ensure maximum efficiency in operation. It can also be used as a de-rusting fluid either in a dip-tank, by brush or by spray application.

Arrow Cleaning & Hygiene Solutions, Rawdon Road Moira, Swadlincote, Derbyshire, DE12 6DA Please call on 01283 221044 or email sales@arrowchem. com, quoting EMS magazine as the subject header.

SCALING PROBLEMS SOLVED Dynamic Descaler is probably the world’s safest and most effective descaler. It dissolves all water scale and lime as well as mud, rust and other non-soluble sedimentation. It’s biodegradable, quick, easy to use (and re-use until spent) and economical. Independent lab tests prove it is the least corrosive descaler available. Keeps plant and systems at peak efficiency Dynamic Descaler lets maintenance engineers save time and cost. Clean equipment uses less energy and lasts longer. Regular use of DD reduces downtime and extends intervals between repair shutdowns. It’s approved and trusted worldwide by big oil companies and automotive manufacturers, and by the US, UK and Australian navies. Dynamic Descaler works in hours and can be diluted, so a little goes a long way. It’s safe on steel, iron, brass, copper, plastic and rubber, so ideal in applications involving any water heating process. For stainless and aluminium, there’s D-Scale 518.

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Before

After

South East Representative Dynamic Descaler UK Ltd. Florence Road Business Park James Coulling Kelly Bray Tel: Callington Cornwall 01424 774275 PL17 8EX Mobile: 07803 056697 e-mail: james.coulling@sky.com

Tel: 01579 384777 Fax: 01579 384765 e-mail: sales@dynamicdescaler.co.uk


PRODUCT SPOTLIGHT – DESCALING

A PREFERRED METHOD OF MAGNETIC FLUID TREATMENT AMONG THE WORLD’S TOP MULTINATIONAL COMPANIES. Life-time descaling & savings.

Satisfaction Guaranteed!

We guarantee permanent descaling & savings by eliminating anti-scaling & anti-corrosion chemical treatment via natural (i.e. chemical-free) water conditioning. Lifetime results & power. No electricity used. Unparalleled ease of installation. No cutting off of pipes, no tools/downtime/maintenance needed. Magnetizer’s unique mono-polar hard water conditioning system is the most powerful and efficient, fully warranted magnetic system available in the world today. When we charge H2O magnetically it takes on a greater ionic charge than the minerals, which creates a natural magnetic attraction between the two. The magnetization then attracts & locks the dissolved minerals into the H2O. The patented Magnetizer energizes and organizes random & clustered water molecules. It ionically rehydrates & dissolves Ca/Mg/other mineral scale build up, resulting in scale-free & electrolytic corrosion-free environment. Our strong, single-focused method neutralizes caustic/hard/ corrosive H2O & curtails corrosion by binding excess hydronium & hydroxyl ions to the H2O molecule. This produces a neutralizing effect and better/cleaner/longer running equipment. Magnetizer naturally softens water through lowered surface tension. It stabilizes pH (balances & buffers it) & fully oxygenates H2O. Improves its quality, which is healthier to consume or use (F&B industry, agriculture, farming), as it contains minerals, improved taste & smell (e.g. ousted sulfur). It enhances the efficiency of biocides, inhibits anaerobic bacteria & algea growth.

Reduces use of flocculants, soap, detergents, shampoos, or chloride/bromide in pools (Cranfield University study available). Works well with filters. Increases thermal transfer efficiency or water pressure. Saves cost & time of sedimentation in sludge (waste) water treatment. Descales evaporators in ships, saline apps (salt conducts EM). Oil wells, golf courses & more.

Scientific papers, test results and Client List available. We invite and encourage you to explore this exciting and environmentally friendly technological breakthrough. Contact: Stefan Zawistowski, Dir. Magnetizer Installations, Mundimex, Inc. (USA) www.mundi.com e: info@mundi.com t: (USA) (718) 846-8429

SHOWERSAN: A COMPLETE SOLUTION TO DESCALE AND SANITISE SHOWERHEADS Hard water is caused by chalk/ limestone found naturally in water. A scaled shower head reduces flow and provides an ideal environment for legionella growth. Legionella bacteria occurs naturally in water and can quickly multiply in scaled/dirty showerheads. Legionnaires Disease can be contracted by inhaling contaminated water droplets from a scaled or dirty shower. Showersan is a ‘ready to use’ product containing a mineral acid descaler to remove limescale and a sanitiser to remove bacteria including Legionella. Showersan is available at £ 61.50 per 20 litre delivered excluding VAT, and contains an indicator to show that it is still active, so can be re-used.

Above: Before and after images of a descaled shower head using SHOWERSAN

BEACON WATER TREATMENTS LTD T 01933 410066 www.beaconwater.co.uk

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PUMP INDUSTRY TECHNOLOGY

AXFLOW TAKES A LOOK AT SEAL-LESS PUMPS Author: Tony Peters, Managing Director AxFlow Limited As an international supplier of pumps and systems AxFlow is in an unbiased position when it comes to evaluating the pros and cons of seal less pumps. Taking static seals first, their sole purpose is to fill a gap to stop liquid flow and, because they are between two fixed surfaces, reliability is fairly assured. However, their performance over the long term can be affected by movement, abrasive erosion, corrosives and attack from chemicals. They can also be ‘blown out’ by over pressure. Whereas designing a static seal arrangement is relatively straight forward, it is more challenging to form and maintain a seal between moving surfaces. For this reason, the designers of rotary dynamic pumps have always sought to find ways of eliminating rotating seals resulting in the emergence of many types of sealless pumps. Seal-less pump types Submersible pumps are fully submerged in the pumped liquid so there are no pressurised seals to the atmosphere – however there is a seal between the pump shaft and motor. Cantilever sump pumps use

Above: Figure 1 Hermetic canned motor pump

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Above: Figure 2 Pulsafeeder diaphragm pumps a centrifugal impeller mounted on a long vertical shaft, with the pumping elements located in the volute casing submerged in a wet pit. The motor and shaft bearings are mounted in a dry position at the top of the pit. Tank pumps are of a similar design, but a wet pit is replaced by a purpose-built tank that houses the vertical pump. Canned motor pumps (Fig. 1) are characterised by their compact and integrated design, with the motor and pump forming a single unit with the rotor and impeller fitted on to a common shaft. The rotor is guided by two slide bearings and the drive motor stator is separated from the rotor using a cylindrical metal can. The rotor compartment, together with the hydraulic section of the pump, is filled with the pumped medium during operation. The heat loss from the motor is carried off by a partial flow between the rotor and stator, and the flow also lubricates both slide bearings in the rotor compartment. The hermetically sealed can and the motor casing offer primary and secondary containment. It is this, together with the compact design and low noise level, which differentiates the canned motor pump from the magnetically coupled pump. The double containment design makes the canned motor pump 100% leak free. Even in the unlikely event of a stator line rupturing there is no leakage to atmosphere. Magnetically driven pumps use a series of magnets attached to the pump shaft contained within a bellshaped housing. Forming a seal-less unit, the pump rotor is driven by magnets on the motor output shaft which is rotated by the motor acting on the pump rotor magnets through the bell housing.


PUMP INDUSTRY TECHNOLOGY of a flexible diaphragm. The pulsating action is the same as for the piston or plunger pump, but significantly the pump does not contain packed seals. With the hydraulically actuated diaphragm pumphead, the diaphragm pumps the liquid by the diaphragm being actuated by the movement of a plunger in hydraulic oil. The diaphragm acts in pressure equilibrium providing extreme reliability. It also acts as a barrier permitting the pumped liquid to come into contact only with materials that have been specified for their resistance to chemical attack or corrosion. Further containment can be achieved by the use of two back-to-back diaphragms with a leak detection system. Air operated double diaphragm pumps For fluids containing high solids content or where hazardous environments demand a leak-free ATEX compliant pump technology, the air-operated double diaphragm pump (Fig.3) stands out. It can transfer heavy, abrasive liquids and slurries equally as efficiently and effectively as fluids that can be damaged by high shear forces, such as those in food processing. Above: Figure 3 Wilden AODD with MizAir compressed air reduction controller Sump, tank, canned and magnetic-drive pumps remove the need for rotary seals and as a result, when applied correctly, they eliminate up to 90% of the problems associated with seal downtime. There is another seal-less pump type that falls between rotary and reciprocating pumps, this being the peristaltic principle, whereby a tube containing the pumped liquid is housed within a semi-circular casing. Rollers, or shoes driven a by a geared motor compress the tube, producing a pulsating squeezing action that moves the liquid in the tube. Diaphragm pumps Mechanically and hydraulically actuated diaphragm pumpheads (Fig. 2) are one of the areas of focus for new developments in metering pump technology. Diaphragm pumpheads are now capable of accommodating hazardous, toxic and dangerous liquids at variable flow rates and pressures. Piston and plunger reciprocating positive displacement pumps present particularly unique challenges with regard to the development of seal-less designs, but many applications can be performed by diaphragm pumps. In mechanical diaphragm pumps the reciprocating action of the piston/plunger via a connecting rod and crankshaft is applied to the centre

When running, the dynamic components that come into contact with the fluid are the two diaphragms which are connected by a common shaft, the two inlet valve balls and the two discharge valve balls. The diaphragms act as a separation membrane between the compressed air supply and the fluid. Portable, straightforward to use and easy to maintain this pump type pump can run dry, selfprime and ‘deadhead’ without any adverse implications.

AxFlow offers sealless pumps from a wide range of manufacturers including Hermetic, Pulsafeeder, Blackmer, Wilden, Almatec, Wernert, King Cobra and Eclipse. For further product details, contact: Tony Peters AxFlow Ltd Orion Park Northfield Avenue Ealing London W13 9SJ Tel: 020 85792111 Email: info@axflow.co.uk www.axflow.co.uk

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INDUSTRY NEWS

HEAT TRANSFER RESEARCH, INC. (HTRI) HTRI Xchanger SuiteŽ is the world’s most advanced software package for designing, rating, and simulating a variety of heat transfer equipment including shell-and-tube, air coolers, plate-and-frame, and spiral exchangers. Additional modules allow for precise modeling of flow-induced vibration and more. For nearly fifty years, HTRI, the global leader in process heat transfer and heat exchanger technology, has conducted proprietary research on custom-built and industrially-relevant rigs to ensure that our software models are the most accurate available. Become a member today and benefit from the power of the consortium. Heat Transfer Research, Inc.

Worldwide 150 Venture Drive College Station, TX 77845 USA Phone: +1.979.690.5050 Fax: +1.979.690.3250 Email: HTRI@HTRI.net www.HTRI.net EMEA (Europe, Middle East, Africa) The Surrey Technology Centre 40 Occam Road Guildford, Surrey GU2 7YG United Kingdom Phone: +44-(0)1483-685100 Fax: +44-(0)1483-685101 Email: HTRI.EMEA@HTRI.net

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PRODUCT SPOTLIGHT – GAS TURBINE MONITORING

LEARN FROM THE GAS TURBINE EXPERT

DR. MEHERWAN P. BOYCE, PHD, P.E., C.ENG (UK) DR. BOYCE, BEST-SELLING AUTHOR, CONSULTANT, AND DEVELOPER OF THE FIRST TOTAL CONDITION MONITORING SYSTEM (MECHANICAL & AEROTHERMAL), WILL PRESENT TWO LIMITED ENGAGEMENTS IN LONDON IN 2011. Improving Efficiency, Productivity and Reliability of Centrifugal Compressors and Gas Turbines July11-13, 2011 Advanced Technology Gas Turbines & Planned Optimization of Combined Cycle Power Plants November 22-24, 2011

A world recognized expert in gas turbines, centrifugal compressors, and combined cycle power plant systems, Dr. Boyce has designed systems for offshore platforms, refineries, natural gas facilities, pipelines, and power plants.  Major corporations, the EPRI, and the U.S. Department of Energy consult with Dr. Boyce on designing and recommending systems. Dr. Boyce’s short courses are interactive and provide practical information with minimal theory. Participants are encouraged to bring challenges specific to their environment for Dr. Boyce to solve. Total Condition Monitoring and turbine and compressor characteristics are discussed in-depth. Secure your spot today! www.boyceconsultancy.com 2121 Kirby Drive, Houston, TX, 77019, USA 1-713-807-0888 zmboyce@boycepower.com PRODUCT SPOTLIGHT - FLOWMETERS

FLOWTECHNIK (DIVISION OF HYDROTECHNIK UK LTD.) Call us now or visit our new website Flowtechnik Unit 10 Easter Park Ind Est Lenton Lane Flowtechnik is a division of Hydrotechnik UK Ltd offering Flowmetering and Instrumentation solutions for fluid flow measurement, display & control. We cater for many different industries and budgets with flows from 0.3 l/hr up to 7000m3/hr and pressures up to 4000 bar. We distribute from a worldwide network of suppliers ensuring a solution to suit mostly all measuring, communication & industry requirements.

Nottingham NG7 2PX Tel: 0800 068 4134 / 0115 900 3550 Fax: 0115 970 5597 E Mail: sales@flowtechnik.co.uk Web: www.flowtechnik.co.uk

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OEE

EVENT ALERTS AND MAINTENANCE TEAMS I spent three productive days at Maintec last month; it’s not as big as it used to be, but it’s still a good place to meet old friends, perhaps even a chance to gain new business. My first involvement with the Maintec gang was the 7th National Conference on Computers for Maintenance Managers, in November 1986, at the Park Lane Hotel in Piccadilly, where a crowd of 280 delegates congregated. I worked for Express Foods Group at the time and my paper was titled ‘Justify Stock Control First’. The paper aimed to demonstrate the the value of computer based spares control as a way of preventing so much time being wasted searching for spares which were probably there, and then inevitably buying a pile more anyway. I do find it frustrating that 25 years later so many large factories have little spares control and ‘guess’ at likely values in excess of £750k. It was, and still is, down to the perceived workload involved in identifying items, which only takes a long time if you never actually start. At that time many sites kept the maintenance teams apart from their production colleagues, probably to keep the fighting and finger pointing to a minimum. It’s good to see things have moved on since then, with most factories now bringing the teams together under the heading of ‘manufacturing’. But there is still plenty of progress to be made to improve communications between teams and embed cross-functional working. So how can we improve real-time communications between operators and maintenance, or between operators and any support service? Let’s use an example. My production process has stopped, or is running slowly, and I need some help. I ring the engineer’s workshop. The ‘best’ engineer, in my opinion, is on holiday, the 2nd best is on another job and I am advised that the 3rd best could be in the canteen. I have a range of mobile numbers, but not one for the engineer in the canteen. In any case this looks like it will be a big job, requiring ‘out-of production’ follow-up, so I would like to raise a works order in the CMMS system. Operators are not permitted to carry out that critical task, so I try to call the engineering team leader but his mobile is engaged. OK, I try the maintenance manager, but he won’t speak to me because I have to go through the right channels first. By this time we have lost many minutes of production time, there is no sign of an engineer, or a work request in our maintenance system. Is there an alternative? If we’re monitoring the production process, in real-time, as part of the measurement of OEE, we have more information and can give the busy operator more help. We have to remember

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an operator is at their busiest during a breakdown, trying to fix the problem, contacting engineering, and letting people know we may ‘short’ this order; they could do with some support. What about a four-step process, without any operator intervention? Provide a display that shows production is slow running and the order will be missed at the current rate Inform everyone production has stopped Contact engineering automatically and escalate the issue Create a work request so nothing is forgotten

Step 1: A simple motivational display

Display the fact that we should have made 10,080 products by now but have only made 7,658 and we are going to miss our expected finish by 30 minutes. The orange circle shows throughput is currently running at below 50% of target speed. The display is highly visible so no one can claim they didn’t understand the state of play. Step 2: A visible stop signal and the reason why


OEE

Step 3: An Automatic Alert

The software has been configured to send an automatic alert by text message to a mobile, and email to confirm. Triggered automatically, because we ‘told’ the software this event is ‘critical’, we have been trying to track it down for some time. We set the message to go to the individual or group accountable for resolving the issue as soon as the event occurred, and then set it to escalate the message to the team leader after 5 minutes, and maintenance and manufacturing managers after 10 minutes of downtime. (The engineer that is on holiday has already re-routed his triggered events to an alternative person until he returns.)

the entire factory’ floor due to ‘slip hazard’ didn’t exactly help the situation.) However this issue is easily overcome by just making sure the person who sets the event triggers retains full control of the process. One final point: Integrated OEE and Maintenance systems form an effective combination - and above all else, we must be effective.

Anything can trigger an event; waste above a certain level, down-time for the shift over 30 minutes, ‘short order’ position, throughput below target. Step 4: A Works Order

We automatically create a works order in our CMMS system, which the engineer receives wirelessly on his new iPad, (creative engineers at this plant!). That prevents the critical issue being missed in the panic, and the task becomes part of the maintenance planning process, and doesn’t get lost in any shift handover. Steps 1- 4 can all happen without a single phone call whilst the operator is busy trying to clear the fault and reporting his findings to his team leader. The escalation process works well as it’s what people do by phone anyway, but this method goes some way to preventing enthusiastic operators ringing the maintenance manager directly. When the manager receives the text message and email he knows the plant has been stopped for a predefined period of time, and that his staff has already been made aware of the issue. Are there downsides? Of course, if it’s not used sensibly and each fault is set to trigger an alert, very few people will take notice of any alert or works order. I remember one company throwing open the ability to allow anyone to create work requests; within weeks the site had 10,000 tasks and the engineers were overwhelmed. (Requests such as ‘re-lay

Alan France, Operations Director of Idhammar Systems, has extensive experience in lean manufacturing with a background that includes several years as Engineering Systems Manager for the largest food company in Europe. A systems specialist, he now consults on the importance of underpinning lean initiatives with realistic targets and sound metrics. Contact him by e-mail, alan.france@ idhammarsystems.com, or visit www. idhammarsystems.com for more on CMMS and OEE software.

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PRODUCT SPOTLIGHT – HYDRAULIC REPAIR

HEAVY EQUIPMENT MAINTENANCE SOLUTIONS LTD (HEMS) IS A SPECIALISED COMPANY WITH OVER 30 YEARS EXPERIENCE FOR SUPPLYING THE LATEST EQUIPMENT FOR THE SERVICING AND MAINTENANCE OF OFF HIGHWAY MACHINES TO THE HEAVY EQUIPMENT AND MINING INDUSTRY WORLDWIDE.

We offer a complete professional service to all Caterpillar, Komatsu, Case, New Holland, Volvo, JCB, Liebherr and many more dealers throughout the world. HEMS are the sole authorised overseas dealer for TUXCO Corporations USA. Tuxco has manufactured cylinder repair benches for many years and they are the main supplier to Caterpillar and are considered the leader in Hydraulic Cylinder Repair Technology. Together, HEMS and Tuxco can offer a complete range of hydraulic cylinder repair stands to cover a wide range of cylinders currently used in the construction and mining industry. HEMS is also the authorised dealer for Maruma Technica Japan and has been working with them to offer a unique package to our customers from complete workshop design, through layout, specification of equipment, supply of equipment, installation, commissioning and, most importantly, operator training. Operator training is a major consideration for HEMS and it can be carried at on‑site or at the Maruma facility in Japan. HEMS works with the customer from day one in understanding their needs and the specific service capabilities that are required for each project site. This is dependant on many factors in regards to size and mix of fleet population, location and level of service capability required etc.

with the CNH (CASE New Holland) group globally for supplying Cylinder Repair Benches to them as well as being recommended to their global dealer network for our range of services and support. HEMS see its market strength in being a totally independent company and not tied to any OEM manufacturer. We offer an exceptional support to all our customers from day one with our valuable experiences in heavy equipment industry and being able to offer unbiased and professional assistance to any construction, mining or large fleet companies that need to have the latest maintenance, service and rebuild tooling.

Heavy Equipment Maintenance Solutions (HEMS) Ltd,Suite 6, St Georges House, 34 – 36 St Georges Road,Brighton, E Sussex. U.K BN2 1ED Tel: 44 1273 686870 - 44 7816987143 Fax: 44 20 7504 3787

HEMS Ltd is very proud to have an on going agreement

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BUYERS GUIDE 2011

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BUYERS GUIDE 2011

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March/April 2011 EMS magazine